Buderus Logano G115 WS US/CA Installation And Service Instructions Manual

For heating contractors

Please read carefully prior

to installation and servicing.

Caution!

Observe the safety instructions of this installation

and maintenance manual before placing the boiler

in operation.

Danger!

If installation, adjustment, modification, operation or

maintenance of the heating system is carried out by

an unqualified person, this may result in danger to

life and limb or property damage.

The directions of this installation and maintenance

manual must be followed precisely.

Contact a qualified service company or service pro-

vider if support or additional information is required.

Caution!

The operating manual is a component of the techni-

cal documentation and must be handed over to the

operator of the heating system.

Discuss the content of this manual with the owner

or operator of the heating system to ensure that

they are familiar with all information required for

operation of the heating system.

Installation and Service

Instructions

Low-temperature

oil boiler

6 720 615 225-00.1RS

Logano G115 WS US/CA

6 720 615 225 - 08/2007 US/CA

Contents

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

2

Contents

1 Safety Considerations and Symbol

Descriptions 3

1.1 Regarding this Manual 3

1.2 Explanation of symbols 3

1.3 Observe the following Symbols 3

1.3.1 Installation Guidelines 4

1.3.2 Boiler Room Guidelines 4

1.4 Tools, Materials and Accessories 4

1.5 Disposal 4

2 Product description 5

2.1 Intended use 5

2.2 Certification and testing mark 5

2.3 Notes on installation and operation 5

2.4 Heating system water quality 5

2.5 Product description 6

2.6 Pack contents 7

2.7 Dimensions Specifications 8

2.7.1 Logano G115 WS dimensions 8

2.8 Conditions for operation 9

2.8.1 General operating conditions 9

2.8.2 Conditions for the boiler room and the

environment 10

2.8.3 Combustion air supply conditions 10

2.8.4 Conditions, Fuel 10

2.8.5 Conditions power supply 11

2.8.6 Conditions for hydraulic system and

water quality 11

3Moving the boiler 12

3.1 Reducing boiler weight for transportation

purposes 12

3.2 Lifting and carrying the boiler 13

3.3 Using transportation aids to transport

the boiler 13

4 Installing the boiler 14

4.1 Wall clearances 14

4.2 Reversing boiler door 15

4.3 Mounting the adjustable feet

(included with B-kit) 16

4.4 Positioning and leveling the boiler 16

5 Installing the boiler 17

5.1 Flue pipe installation 17

5.1.1 Chimney venting 17

5.2 Fitting the water connections 19

5.2.1 Fitting the B-kit 19

5.2.2 Installation of boiler drain (included in B-Kit) 20

5.2.3 Installing system components 20

5.3 Filling the heating system and checking

for leaks 21

5.4 Mounting the burner 23

5.5 Connecting the fuel supply 23

5.6 Installing aquastat 24

5.7 Blocked vent switch (required in Canada) 24

5.8 Electrical connections 24

5.8.1 Fitting the controls 25

5.8.2 Fitting temperature sensor assembly

and burner cable 26

5.8.3 Connecting the power supply and additional

components 27

5.8.4 Fitting cable ties 27

5.9 Fitting outer casing panels 27

6 Commissioning the heating system 28

6.1 Bringing the system up to operating pressure 28

6.2 Checking the safety valve 28

6.3 Checking position of heat exchanger baffles 29

6.4 Preparing the heating system for operation 29

6.5 Starting up the control and the burner 29

6.6 Notes on commissioning the burner 30

6.7 Raising flue gas temperature 30

6.7.1 Adjusting the position of heat exchanger

baffles 31

6.7.2 Removing heat exchanger baffles 31

6.7.3 Removing the heat exchanger barrier plate 32

6.8 Manual reset high limit (STB) 32

6.9 Installing the burner door jacket 32

6.10 Commissioning log 33

7 Shutting down the heating system 34

7.1 Shutting down normally 34

7.2 Shutting down the heating system in an

emergency 34

7.2.1 What to do in an emergency 34

8 Heating system servicing 35

8.1 Why is regular maintenance important? 35

8.2 Preparing the boiler for servicing 35

8.3 Cleaning the boiler 36

8.3.1 Cleaning the boiler with brushes 36

8.3.2 Wet cleaning (chemical cleaning) 37

8.4 Checking heating system operating pressure 37

8.5 Testing relief valve 38

8.6 Servicing and maintenance logs 39

9 Troubleshooting 42

10 Installation examples 43

11 Parts lists 45

12 Circuit diagrams 50

1

Safety Considerations and Symbol Descriptions

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

3

1 Safety Considerations and Symbol Descriptions

1.1 Regarding this Manual

This document contains important information regarding

safe and proper installation, operation and maintenance of

the boiler.

The high tech G115 WS boiler is designated as a hot

water heating boiler.

The Installation and Maintenance Instructions are directed

to the installing contractor who has professional knowl-

edge regarding boiler installation and maintenance.

1.2 Explanation of symbols

Signal words are used to indicate the seriousness of the

ensuing risk if measures for minimising damage are not

taken.

– Caution indicates that minor damage to property may

occur.

– Warning indicates that minor personal injury or severe

damage to property may occur.

– Danger means that severe personal injury may occur.

Very serious cases may result in death.

Notes contain important additional information.

Notes do not contain any warnings or information about

hazards or risks.

1.3 Observe the following Symbols

All applicable local, state, and national codes and regula-

tions must be observed for the installation of the boiler:

– The local building code requirements regarding place-

ment, combustion air and venting and chimney system

must be followed.

– Follow applicable electrical code requirements.

– Follow the local code and standards regarding safe

boiler operation.

Warnings are indicated by a warning triangle

and a grey background.

Notes are identified in the text by this symbol.

They are bounded by horizontal lines above

and below the text.

NOTICE

Use only original Buderus spare parts.

Buderus can not be held liable for damage

caused by non-Buderus parts.

NOTICE

The boiler installation must be performed by

a qualified installer in accordance with regu-

lations put forth in NFPA-31 Installation of

Oil-Burning Equipment. The installation must

comply with all local and national codes, reg-

ulations and authorities having jurisdiction re-

garding the installation of oil fired boilers.

For Canada refer to the guidelines of CSA/

CGA-B139 Installation Codes.

1

Safety Considerations and Symbol Descriptions

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4

1.3.1 Installation Guidelines

1.3.2 Boiler Room Guidelines

1.4 Tools, Materials and Accessories

For the installation and maintenance of the boiler you will

need typical tools used in this industry.

In addition, the following components are useful:

– Hand truck with strap or Buderus boiler cart.

– Wood blocking.

– Cleaning brushes and/or chemical cleaning agents for

wet cleaning.

1.5 Disposal

V Please dispose of any trash in an environmentaly

friendly fashion.

V Please discard properly of any heating system related

components.

Caution: DANGER TO LIFE

from electric shock.

V Do not work on electrical components un-

less you have the required qualification.

V Do not work on electrical components un-

less you have the required qualification.

V Prior to opening the control: shut down

the power supply by turning off the emer-

gency shut-off switch or disengaging the

heating system circuit breaker, and pre-

vent from accidental reactivation.

V Observe all applicable installation guide-

lines.

Caution: DANGER TO LIFE

from flue gas poisoning.

Insufficient combustion air can result in dan-

gerous operation if combustion air is taken

from indoors.

V Please observe that combustion air open-

ings are not reduced in size or closed.

V Make sure that no mechanical air open-

ings or devices remove combustion air

from the boiler room such as central vacu-

um systems, dryers and air conditioning

appliances.

V Make sure that the boiler is connected to

a chimney or horizontal venting system

that is capable of handling the slight posi-

tive breeching pressure.

V If any of these problems have not been

corrected, the boiler must not be operat-

ed.

V Make the end-user aware of these guide-

lines and their potential danger.

Caution: FIRE DANGER

due to flammable or liquid materials.

V Make sure that flammable and liquid mate-

rials are not stored in the close vicinity of

the boiler.

2

Product description

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5

2 Product description

This installation and maintenance manual contains impor-

tant information for the safe and intended installation, ini-

tial start-up and maintenance of this boiler.

The special oil fired boiler Logano G115 WS is generally

referred to below as a boiler.

The installation and maintenance manual is provided for

technicians who have been trained and have experience

in working with heating systems and oil fired installations.

2.1 Intended use

The G115 WS is designed for central heating and

domestic hot water (DHW) systems, for instance in resi-

dential homes or apartment buildings, or small commer-

cial applications.

2.2 Certification and testing mark

This appliance has been tested and certified to meet rules

and regulations in place for the US and Canadian mar-

kets.

2.3 Notes on installation and operation

When installing and operating the heating system, it is the

installer's responsibility to meet all applicable federal,

state, and local codes.

2.4 Heating system water quality

Poor water quality can damage heating systems due to

scale formation and corrosion.

Please refer to Chapter 2.8.6, Tab. 9 for further details of

the water quality.

Caution: Risk of system damage due to un-

suitable boiler water.

V If oxygen-permeable pipes are used, e.g.

for radiant heating systems, the systems

must be separated from the boiler by a

heat exchanger. Unsuitable heating sys-

tem water promotes sludge formation and

corrosion. This can result in heating sys-

tem malfunction and boiler damage.

2

Product description

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6

2.5 Product description

The boiler is a low-temperature oil-fired appliance with

automatic control panel or aquastat for boiler water tem-

perature.

The boiler consists of:

– Boiler heat exchanger with insulation

– Boiler jacket

– Control panel or aquastat

The controls monitor and control all electrical boiler com-

ponents.

The boiler can alternatively be fitted with a simple aqua-

stat control.

The boiler jacket prevents heat loss and acts as a noise

insulator.

The boiler heat exchanger transfers the heat generated by

the burner to the heating water. The insulation prevents

energy loss.

Suitable burners

Fig. 1 Boiler without burner

1 Control panel

2 Boiler jacket

3 Boiler heat exchanger with insulation

4 Burner door

5 Burner door panel

Caution: Risk of system damage from use

of incorrect burner.

V Only the burner provided may be em-

ployed with this boiler.

6 720 615 225-01.1RS

1

2

3

4

5

2

Product description

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7

2.6 Pack contents

Upon delivery, check that the packaging is complete and

undamaged.

Component Qty Packaging

Boiler heat exchanger 1 1 pallet

Boiler casing, factory-fit-

ted to boiler heat

exchanger

Burner door and burner

door panel, factory-fitted

to boiler heat exchanger

B-kit components:

– 1 Supply manifold

G115"US"

– elbow 90 ° 1-1/4"

– elbow 90 ° 3/4"

– double nipple R1-1/4"-

1-1/4" NPT x 75

– boiler drain 3/4"

– relief valve 3/4" x 3/4"

30PSI

– temperature/pressure

gauge

– Bolt set B-Kit

G115"US"

– adjustable boiler feet

M10 x 51 packed

1 1 foil package

1)

1) in the combustion chamber in the boiler

Controller or, alternatively,

Aquastat

2)

2) Aquastat may be supplied with burner

11 box

Technical documentation 1 foil package

Tab. 1 Package Contents

2

Product description

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8

2.7 Dimensions Specifications

2.7.1 Logano G115 WS dimensions

Fig. 2 Connections and dimensions (measurements in inches)

VK = Boiler supply

RK = Boiler return

EL = Boiler drain (connection for drain valve)

Connections and dimensions:

7 747 019 141-02.1RS

23

5/8"

L

VK

L

K

F

L

39

5/8"

30

3/8"

1

3/4"

2

7/8"

8

7/8"

8

7/8"

Rp1

1/4"

EL

Rp

3/4"

2

7/8"

25

1/4"

RK

1" NPT

3

1/4"

Ø 5"

20"

10

3/8"

12

1/4"

5

7/8"

4

3/8"

5/8"

- 1"

Boiler model Unit G115/3 WS G115/4 WS G115/5 WS

Boiler sections 345

Heating capacity (gross output) MBtu/hr 85 109 136

Thermal output (net IBR output) MBtu/hr 74 95 119

Boiler water content Gal 8.7 10.8 12.9

Gas capacity cu.ft. 1.20 1.75 2.21

Oil firing rate GPH 0.7 0.9 1.0

Flue gas back-pressure W.C. 0.04" - 0.06"

Permissible flow temperatureSafety

1)

1) Limit (safety temperature limiter, STB)

Maximum permitted flow temperature = Safety limit (STB) - 32 °F

Example: Safety limit (STB) = 212 °F, maximum permitted flow temperature = 212 ° - 32 ° = 180 °F

The safety limit must meet the national regulations of the country concerned.

°F 230

Allowable operating pressure psi 58

Maximum time constant of thermostat and

high limit safety cut-out (STB)

s 40

Tab. 2 Technical data for boilers without burners

Boiler model Unit G115/3 WS G115/4 WS G115/5 WS

Boiler overall length (L) Inch 23-5/8" 28-5/8" 33-3/8"

Boiler block length (LK) Inch 21-1/8" 25-¾" 30-½"

Combustion chamber length Inch 16" 20-½" 25-¼"

Combustion chamber length Inch 10-5/8"

Burner door thickness Inch 3-5/8"

Distance between boiler feet (FL) Inch 10-3/8" 16-1/8" 20-7/8"

Net weight

1)

– Lbs 330 403 476

Tab. 3 Dimensions, weight and other data for boilers without burners

1) Incl. packaging material approx. 6-8 % more

2

Product description

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

9

2.8 Conditions for operation

Maintaining the specified operating conditions will enable

the boiler to provide a high level of reliability and long serv-

ice life. Some details relate only to operation with Buderus

Logamatic control panels.

2.8.1 General operating conditions

Caution: Risk of system damage if operating

conditions are not maintained.

Irreversible damage to individual compo-

nents of the boiler as a whole or the heating

system may occur.

V The information on the rating plate is bind-

ing and must be observed.

Operating conditions

Min. boiler water tempera-

ture

Operating interruption

(complete boiler shutdown)

heating circuit with

heating circuit mixing valve

1)

Min. return temperature

In combination with Logamatic control for variable low-temperature operating modes, such as Logamatic 2107

no requirements operating

temperatures are ensured by

the Logamatic controls

2)

Automatically by Logamatic controls not required but recommended with

low-temperature heating system

design 130/113 °F

Required with:

– Underfloor heating systems

– Systems with high water content:

> 115° gal/MBH

(1 MBH = 100.000 Btu/hr)

In conjunction with a Logamatic controls for constant boiler water temperatures, e.g. Logamatic 2109 or with supplementary exter-

nal programmer and aquastat

150 °F

3)

possible if, after interruption of the

operation, there is at least 3 hours

heating operation

required Required with:

– Systems with high water content

> 115 gal/MBH: 130 °F

Tab. 4 General operating conditions

1) A heating circuit with a mixing valve improves controllability and is specifically recommended for systems with several heating zones.

2) If heating zones or a boiler circuit actuator cannot be regulated via the control device (for example pump logic), an operating temperature of

122 °F must be reached within 10 min of switching the burner ON by restricting the water volume flow.

3) Boiler water temperature control setting: when the boiler is in ON mode, the minimum boiler water temperature in the boiler must be reached

within 10 minutes, e.g. by flow rate limitation, and maintained as the minimum temperature.

2

Product description

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10

2.8.2 Conditions for the boiler room and the environment

2.8.3 Combustion air supply conditions

If the burner is to be operated with sealed combustion by drawing its combustion air solely from the outdoors, follow

burner manufacturer's specification.

2.8.4 Conditions, Fuel

Operating conditions Notes – Requirement in greater detail

Temperature in the boiler room +40 to +104 °F

relative humidity max. 90 % No condensation or precipitation inside the boiler room

Dust/airborne particles − Excessive dust inside the boiler room must be avoided when the boiler is operat-

ing, e. g.:

– Dust from building work

Combustion air supplied from outside must not be excessively loaded with dust

or airborne particles; if necessary, air filters should be fitted in case:

– Air supply contaminated with dust from dirt roads and paths.

– Air supply contaminated with dust from production and processing facilities, e. g. quar-

ries, mines, etc.

– Airborne particles from thistles and similar

Halogenated-hydrocarbon com-

pounds

− The combustion air must be free from halogenated-hydrocarbon compounds.

– Identify the source of halogen-hydrocarbon compounds and seal it off. Where this is

impossible, route combustion air from areas that are not contaminated by halogen-

hydrocarbon compounds.

Fans that extract air from the

boiler room.

− During burner operation, no mechanical air handling equipment may be operated that could

extract combustion air from the boiler room, e.g.:

–Exhaust hood

– Tumble dryer

– Ventilation equipment

Small animals − Prevent small animals from entering the boiler room, particularly through the air inlet vents –

by fitting them with screens.

Fire safety − Maintain clearances between the boiler and flammable materials in accordance with local

regulations. A minimum clearance of 16" is required. Never store flammable materials or

liquids in the vicinity of the boiler.

Flooding − In case of an acute risk of flooding, disconnect the boiler in time from its fuel and power

supply before water enters the room. Any components or control equipment, which came

in contact with flood water, must be replaced before re-commissioning.

Tab. 5 Boiler room and ambient conditions

Operating conditions

Boiler output (in case of

multi-boiler systems = total output)

Ventilation air cross-section in square inches

(unrestricted aperture)

Air intake flow cross-section for

combustion air drawn from out-

side (divided between max. 2

apertures)

< 170,000 Btu/hr At least 23.25 square inches

Tab. 6 Observe national regulations for boilers which draw their air supply from the boiler room.

Operating conditions Notes – Requirement in greater detail

Permissible fuels for boilers with-

out integral burners

− This boiler can be operated with #2 Fuel Oil ASTM D396-05 Type 2. Select a burner that

is suitable for this fuel typ.

Contamination − Free of contaminants (for example dust, mist, humidity), i. e. a constant operation will not

lead to accumulation of deposits, in valves, strainers and filters and could lead to service

calls.

Tab. 7 Fuels

2

Product description

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11

2.8.5 Conditions power supply

2.8.6 Conditions for hydraulic system and water quality

Operating conditions Notes – Requirement in greater detail

Power supply voltage 120 V

AC nominal

Observe the voltage range of the burner and controls used. The outer casing/boiler must

be grounded for safety reasons and in order to function correctly.

Circuit breaker 10 A

Frequency 60 Hz

Enclosure rating − IP 40 (protected against contact by entry of foreign objects > 0.04 inches Ø

(> 1 mm Ø ), no water proofing)

Tab. 8 Power supply

Operating conditions Notes – Requirement in greater detail

Operating pressure (above

atmospheric)

15–58psi Maximum 30 psi with the supplied safety valve.

Permissible site test pressure 45 – 75 psi

Safety temperature limitation by

TR temperature control

122–194°F

Safety temperature limitation by

manual reset high limit (STB)

212 – 248 °F On some controls adjustable on site from 212 to 248 °F.

Water quality − The heating system may only be filled and topped up with water of domestic water quality.

We recommend a pH value of 8.2 – 9.5.

Tab. 9 System configuration and water quality

3

Moving the boiler

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12

3 Moving the boiler

This chapter details how to move the boiler safely.

3.1 Reducing boiler weight for transportation purposes

If required, you can reduce the weight of the boiler by

removing the burner hood and door.

V Unscrew the burner door-panel screws.

V Lift burner door panel slightly and draw forward to

remove.

Fig. 3 Removing burner door panel

V Unscrew two hex-head bolts at the sides.

V Open burner door.

V Lift the burner door off its hinges.

Fig. 4 Removing the burner door

Caution: Risk of system damage from im-

pact.

Fragile components could be damaged.

V Observe the transport instructions on the

packaging.

Protect boiler connections from damage and

dirt if the boiler is not installed immediately.

Dispose of packaging in an environmentally

responsible manner.

6 720 615 225-02.1RS

Prevent the burner door from falling over and

damaging the burner and blast tube.

7 747 019 141-04.1RS

3

Moving the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

13

3.2 Lifting and carrying the boiler

The boiler can be held and carried at the grip positions

shown.

V Undo the transit screws.

Fig. 5 Lifting and carrying the boiler

3.3 Using transportation aids to transport the boiler

Moving the boiler with hand truck

V Place the hand truck (e.g. boiler trolley or sack truck) at

the back of the boiler.

V Secure boiler to hand truck using the boiler bolts or

strapping.

V Move the boiler to the installation location.

Fig. 6 Moving the boiler with a boiler hand truck

The boiler is secured to the pallet by 2

screws for transportation purposes.

Caution: Risk of injury from carrying heavy

loads.

V Always lift and move the equipment with

the assistance of another person using the

handle positions shown.

7 747 019 141-05.1RS

Caution: Risk of injury if load is inadequately

secured during transportation.

V Use suitable means of transportation, e.g.

the Buderus boiler hand truck with strap.

V Secure the load against falling.

You can order the boiler hand truck from your

Buderus distributor.

The boiler trolley can also be used to facilitate

work underneath the boiler, e.g. fitting the ad-

justable feet (Æ Chapter 4.3, page 16).

7 747 019 141-06.1RS

4

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

14

4 Installing the boiler

This chapter describes how to install and place the boiler

in the boiler room.

4.1 Wall clearances

Position the boiler with the recommended wall clear-

ances. Reducing the minimum clearances makes the

boiler more difficult to access during installation, mainte-

nance and cleaning.

The boiler base or foundation must be perfectly flat and

level.

The burner door is factory-fitted with the hinges on the

right. The burner door can be converted to open to the left

(Chapter 4.2, page 15).

Fig. 7 Boiler room clearances (boiler positioned on the

l.h. or r.h. side)

Caution:

Risk of system damage from freezing.

V Install the heating system in a frost-free

room.

Dimen-

sion

Wall clearance

A Recommended 51-1/8"

minimum 39-3/8"

B Recommended 27-½"

minimum 15-¾"

C Recommended 15-¾"

minimum 3-7/8"

L

K

Æ Chapter 2.7.1 "Logano G115 WS

dimensions", page 8

Tab. 10 Recommended and minimum wall clearances

(dimensions in inches).

7 747 019 141-07.1RS

The boilers are designed for a side clearance

of 6".

Where applicable, allow extra wall clearanc-

es for additional components such as DHW

tank, pipe connections, flue gas silencer or

other flue components, etc.

Caution: Risk of fire from flammable materi-

als or liquids.

V Clearances less than 6" must comply with

local and statutory codes.

V Make sure that there is a sufficient clear-

ance between combustible materials and

the chimney connection as specified by

NFPA 31 (distance of 18 ").

V The floor must comply with the require-

ments of NFPA 31.

4

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

15

4.2 Reversing boiler door

The burner door is factory-fitted with the hinges on the

right – the burner door opens to the right.You can change

the burner door hinges over to the left-hand side if desired

to suit the installation site.

Remove the burner hood/burner door panel first

(Æ Chapter 3.1, page 12).

V Removing the burner door (Æ Chapter 3.1, page 12).

V Unscrew the hinge bolts and remove the hinges.

V Mount the hinges on the left-hand side of the boiler

using the hinge bolts.

Fig. 8 Reversing the burner door (boiler heat

exchanger attachments)

1 Hinge bolts

2 Hinges

V First remove the hinge lobe bolts and then the hinge

lobes. Mount the hinge barrels on the left-hand side of

the boiler using the hinge-barrel bolts.

V Hook the burner door with the hinge lobes onto the

hinges.

V Check that the heat exchanger baffles are placed hori-

zontally (Æ Chapter 6.3, page 29).

V Close the burner door and secure with the two hexa-

gon-head bolts.Tighten the hexagon-head bolts evenly

(approx. 90 Lbs/inch) so that the burner door seals

properly.

Fig. 9 Reversing the burner door (door attachments)

1 Hinge-barrel bolts

2 Hinge lobes

3 Burner door

4 Hinges

5 Heat exchanger baffle plates

7 747 019 141-08.1RS

12 21

If the burner door hinges have been changed

over to the left-hand side, the burner cable

must be disconnected from the burner before

opening the burner door.

7 747 019 141-09.1RS

1

4

5

2

3

4

Installing the boiler

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16

4.3 Mounting the adjustable feet (included with B-kit)

Level the boiler with the adjustable feet to prevent air

pockets forming inside the boiler.

Requirement: the burner hood/burner door panel must

have been removed first (Æ Chapter 3.1, page 12).

V Tilt the boiler with the aid of a hand truck or trolley

(Æ Chapter 3.3, page 13) or place a wooden batten

underneath it.

V Screw in adjustable feet ¼" – 3/8".

V Gently set the boiler down.

Fig. 10 Fitting adjustable feet

1 Angle bracket

2 Adjustable feet

4.4 Positioning and leveling the boiler

V Position the boiler in its final location.

V Level the boiler horizontally by turning the adjustable

feet and using a level.

Fig. 11 Leveling the boiler horizontally

If the boiler is mounted on top of a horizontal

hot water tank, the adjustable feet are not

needed.

7 747 019 141-10.1RS

1

2

Protect boiler connections from damage and

dirt if the boiler is not installed immediately.

7 747 019 141-11.1RS

5

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

17

5 Installing the boiler

This chapter details how to install your boiler correctly.

The individual steps involved are:

– Connecting the flue

– Connecting the water pipes

– Making the electrical connections

– Fitting the burner

– Connecting the fuel supply

5.1 Flue pipe installation

5.1.1 Chimney venting

Connect boiler to vertical chimney with a 5" vent pipe.

Use only venting systems that comply with local codes

and regulations.

If local codes are not existent, refer the the following reg-

ulations:

– NFPA 31, Installation of Oil-Burning Equipment,

– NFPA 211, Standard for Chimneys, Fire Places and

Solid Fuel Burning Appliances,

– In Canada refer to CSA B139, Installation Code for Oil-

Burning Equipment,

– NFPA 211 requires chimney to be lined before con-

necting boiler.

Inspecting and cleaning existing flue

Before installing the new boiler, check and clean the old

flue system.

V Remove blockages and dirt from the chimney.

V Clean chimney.

V Repair or replace faulty sections.

V If necessary, repair chimney with mortar and joints.

Down drafts

To prevent down drafts extend chimney at

least 3 feet above the roof opening and at

least 2 feet above any part of the roof within

a radius of 10 feet.

5

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

18

Minimum clearances to combustible material

Minimum size of chimney

The minimum recommended chimney size is 8" x 8"

(6 ¾" x 6 ¾" inside liner) or 6" diameter with a minimum

height of 15 feet. Use a 5" flue pipe for connection to an

existing chimney.

Installing the flue pipe

V Insert flue pipe 5" onto the breach and secure with

3 screws.

V Install flue connections between boiler and chimney to

slope up at least ¼" per foot to the chimney.

V Connect the flue pipe to the chimney above the bottom

of the chimney to prevent blockages.

V Install cleaning and service hatches.

After starting the burner, set breeching draft to -0.01 to

-0.02 inches WC using a draft gauge. The overfire pres-

sure can be positive. If necessary, install a barometric

damper in the flue system to maintain the underpressure

in the system or to meet code requirements. Always install

the draft controller in vertical position. Use a draft gauge

when making adjustments.

Fig. 12 Installing the flue pipe

1 Flue pipe

2 Boiler flue socket

Flue pipe Type Minimum clearance

Double-wall L 6"

Single-wall L 18"

Tab. 11 Minimum clearances to combustible objects for

flue systems

Danger: Risk of death from escaping flue

gases.

If the resistance to flue gas flow is too great

and/or the flue pipe diameter is smaller than

the recommended size and/or the flue pipe is

too short:

V Seal all vent pipe joints.

V Install a CO alarm. Positive pressure com-

bustion ensures that the flue gas can exit

the flue system.

Avoid long horizontal flue pipe runs and keep

the number of elbows to a minimum.

5

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

19

5.2 Fitting the water connections

5.2.1 Fitting the B-kit

The safety relief valve and the pressure/temperature

gauge are mounted on the supply manifold (included in B-

Kit) on the VK boiler supply connection as follows:

V Fit and seal unmarked end of double nipple into con-

nection VK on the boiler.

V Converter is paint-marked pink and stamped with the

designation NPT on the end with the 1¼" NPT thread.

Fig. 13 Checking thread length on double nipple

V Seal 90° 1¼" NPT street elbow on double nipple.

V Fit and seal manifold to 90° elbow. The manifold can

face in different directions (Æ Fig. 14).

V Seal pressure/temperature gauge to supply manifold.

Fig. 14 Installing B-Kit

1 90° 1¼" NPT street elbow

2 Double nipple

3 Supply manifold

4 Pressure/temperature gauge

5 Pressure relief valve

6 90° ¾" NPT elbow

Caution: Risk of system damage from leak-

ing connections.

V Support the pipes to the boiler to prevent

them from being under stress.

Do not fit the safety valve until the leak test

(Æ Chapter 5.3, page 21) has been com-

pleted.

The relief valve must be installed in a vertical

position.

We recommend installing a dirt filter (option-

al) in the boiler return connection to reduce

build-up of debris on the water side.

5

Installing the boiler

Logano G115 WS US/CA - Technical specifications are subject to change without prior notice.

20

5.2.2 Installation of boiler drain (included in B-Kit)

V Seal boiler drain to connection EL.

Fig. 15 Installation of boiler drain

RK Return

EL Drain

5.2.3 Installing system components

See the installation diagram for installation of the heating

system components.

For more installation examples refer to Æ Chapter 10,

page 43.

Fig. 16 Installation diagram

1 Pressure relief valve

2 Pressure/temperature gauge

3 Ball or stop valve

4 Air eliminator (in main supply)

5 System pump

6 Flow check valve

7 Expansion tank

8 Automatic feed valve

9 Flow check valve

10 Purge station

11 Water feed

VK Boiler supply

EL Drain

RK Return

Install a fill connection in the supply piping to

the boiler.

7 747 019 141-15.1RS

RK

EL

7 747 019 141-16.1RS

1

2

33 563

3

7

3

98

VK

RK

11

EL

4

10

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Buderus Logano G115 WS US/CA Installation And Service Instructions Manual

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